Apparatus for assembling electrical contacts



P 1963 P. H. BURROUGHS ETAL 3,104,457

APPARATUS FOR ASSEMBLING ELECTRICAL CONTACTS Filed Aug. 9. 1960 2Sheets-Sheet l Bfikfn E1558 INVENTORS AT ORNEY UGHS STON p 1963 P.HABURROUGHS ETAL ,1

APPARATUS FOR ASSEMBLING ELECTRICAL. CONTACTS Filed Aug. 9, 1960 2Sheets-Sheet 2 PAUL H. BURROUGHS DONALD L. KINGSTON NTORS fl/Q/ AT ORNEY3,104,457 APPARATUS FUR ASSELING ELECTRICAL CONTACTS Paul H. Burroughs,Beverly, and Donald L. Kingston, Marblehead, Mass, assign'ors toSylvania Electric Products Inc., a corporation of Delaware Filed Aug. 9,1961i, Ser. No. 53,332 2 Claims. (Cl. 29-203) This invention relates toa novel apparatus for inserting electrical contact elements into anaperture provided in a solid plate. More specifically, this inventionrelates to an apparatus for inserting an insulated electrical contactmember into an aperture in an electroluminescent lamp wherebyelectricity may be conducted to an electrode.

In the construction of an electroluminescent lamp a solid plate, usuallyprepared of metal, is used as a first electrode. A layer of lightemitting material, including an electroluminescent phosphor, is fused tothe first electrode. Above the layer of phosphor is a transparentconductive film which serves as the second electrode. By connectingthese electrodes to a source of electricity, the phosphor is caused toemit light. In order to give stability to the lamp and protect thephosphor from the attack of humidity, a layer of transparent ceramicglaze is fused over the conductive film. To conduct electricity from thesource to the second electrode, a small electrical contact element isinserted in an aperture provided in the lamp. This electrical contactelement usually is a piece of tempered wire. In order to preventshorting out across the first and second electrodes of the lamp, theelectrical contact element is insulated about its middle just below thebend. This insulation not only inhibits the shorting out of the lamp,but also provides a biasing surface so that the contact may be firmlyinserted in the aperture of the lamp. Suitable plastic or rubber may beutilized as this insulation. In practice, it is generally found that ifthe aperture is square and the insulation is also square, uniforminsertion of the contact element will be insured. Furthermore, theinsulation of the contact element is designed so that it is slightlytapered and ends in a biasing stop or flange. By this means, when thecontact is inserted in the aperture, it will be firmly seated. Theaperture usually is of a slightly smaller dimension than the insulatingmember.

Prior to this invention, it was generally the practice to manually graspthe electrical contact elements and then grasp the lamp. It was thenseated by a manual operation in the aperture. The partially assembledunit was then inserted into a jig, a staking tool was actuated and thecontact member firmly seated. These contact elements are quite small,usually less than three quarters of an inch high and about one eighth ofan inch wide. Thus, they are quite diflicult to grasp manually, therebyincreasing the amount of work required for their insertion. It isapparent that manual insertion is substantially slower and causessubstantial delay in production. With the automatic transfer and stakingof this invention, many of these problems are avoided.

In an effort to eliminate these manual operations, it was discoveredthat electrical contacts could be moved automatically from a large batchto an appropriate position in the lamp if the transfer device of thisinvention were used. Through the use of a batch feed the individualhandling of the relatively small contact members can be avoided. Whenthe appropriate jigs are used,the electrical contacts are alwayssimilarly positioned in all lamps produced. It is essential that thecontact member be so placed since, in order to conduct electricity tothe conductive film through this contact, it is necessary to reatentmove a small portion of the insulating glaze coat, usually a spot lessthan /3 inch in diameter. The tip of the electrical contact element mustbe positioned in this spot; if it is positioned over the ceramic glaze,no electrical contact will be made and the lamp will not light.

It is an object of this invention to provide a means whereby anelectrical contact element is automatically inserted in the samerelative position in an aperture provide in an electroluminescent lamp.

It is a further object of this invention to provide a means forautomatically inserting contact elements having an insulation memberaround the middle thereof in an electroluminescent lamp so thatelectrical contact is made.

It is a feature of this invention that all the electrical contactelements are inserted in exactly the same position in all of the lampsbeing prepared, and that all manual positioning is eliminated.

Other objects, features and advantages of this invention will becomeapparent to those skilled in the art upon the reading of the followingspecification when taken in connection with the accompanying drawings.

FIGURE 1 is a front elevational View of the automatic electrical contactassembly device of this invention.

FIGURE 2 is a side elevational view of the electrical contact insertionassembly of this invention.

FIGURE 3 is a top plan view of the assembly equipment.

FIGURE 4 is an enlarged cross-section of the transfer assembly takenalong the line 44 of FIGURE 5.

FIGURE 5 is an enlarged cross-section of the transfer assembly takenalong the line 55 of FIGURE 1.

In each of the figures of the drawings, similar numerical designationsrefer to similar elements of this invention.

Referring now to FIGURE 1, which is a detailed showing of the entiresystem, the vibrating table 1 is positioned behind the motor 5 whichdrives staking tool 9. The vibrating table 1 serves as a batch source ofthe electrical contact elements. The vibration in support assembly 2transmitted to table 1 results in the gradual movement of the electricalcontacts up a helical path 41 (as shown in FIGURE 3) to a rejector 4,which removes all of the contacts which are not in the proper positionto be fed into the chute 8 whereby a uniform positioning therein isinsured.

The staking tool assembly consists of motor 5, chuck 7 and stakingtool'9.' The staking tool is actuated and travels down a vertical pathinto the channel formed by the jaws of the exit guide 26. When thestaking tool 9 enters the channel, it engages the electrical contact andinserts it into the aperture of the lamp. The jaws are spaced apart toaccommodate the end of the contact which will touch the open spot in theceramic glaze. The Variac 36 controls the force with which the tool 9strikes the electrical contact and the turn-screw 47 controls the depthof dwell of the tool. The motor 5 may be a solenoid and when the voltageis changed by adjusting the Variac 36, the staking tool 9, which isoperatively associated with motor 5, will be driven with a differentforce.

The link 11 connects lever arm 13 and carrier arm 6. Lever arm 13 ispivotally mounted on pivot rod 31 which i s in pivot support 25 andlever support 42. The Web 23 is positioned at the intersection of leverarm 13 and lever support 42. This web is provided so that the interlockswitch '21 is actuated when the lead edge 3-3 of carrier arm 6 isdirectly beneath the staking tool 9. By means of switch 21 the interlockarrangement prevents the accidental actuation of staking tool 9 andprevents it from damaging the lead edge 33 of the carrier arm 6. Whenthe lead edge 33 is removed from the jaws of exit guide 26, the switchwill again permit the downward .3 movement of the staking tool 9.Positioned on the carrier arm 6 is stop 28 which contacts adjustablestop 29. This contact prevents the movement of the lead edge 33 of thecarrier arm 6 beyond the desired position in the channel formed by thepair of jaws 26 of the exit guide assembly. As will be noted in FIGURE3, switch 21 is actuated and stop 28 is directly contacting adjustablestop 29 when the lead edge of carrier arm 6 is in the jaws of exit guide26.

The remainder of the transfer assembly comprises the feeding sectionchannel 35 whichintersects chute 8 and is operatively associatedtherewith for feeding contact elements from the chute to the feedingchannel as shown in FIGURE 3. The shape of this channel generallyconforms to the peripheral shape of the carrier arm 6. The contactelements are picked up by the lead edge 33 of carrier arm 6 and aremoved from the first position at the intersection of chute 8 and feedingsection 35 to the second position in the channel formed between the jaws26 of the exit guides. When the lead edge 33 is withdrawn from thetransfer channel 35 past the intersection of chute 3, the nextelectrical contact element is forced into position in the transferchannelby the Weight of the electrical contacts lined up in the chute.The cooperation of chute guide 37 and the horizontal surface at the endof the chute 8 prevents a binding of the electrical contacts as theymove from the chute to the transfer channel. The transfer channel 35 isjust slightly larger than the width of the electrical contact thusallowing only a single electrical contact element to pass into thechannel at a given operation of carrier arm 6. The depth of channel 35is sufficient to permit the free movement of the electrical contactelement. A ridge 4-4 is provided on the side of the channel 35 to permitthe biasing stop or flange surface of the contact element to slide alongits length.

Positioned at the end of the transfer assembly is the exit guide meanscomprised of two substantially identical jaws 26 which cooperate to forma channel. These exit guide means grasp the electrical contact after ithas been transferred by carrier arm 6 and hold it in a ready positionfor insertion into the aperture of the lamp by the staking tool. Springmeans may be provided on the jaws, so that they are maintained at theappropriate separation, taking into consideration the width of thebiasing stop surface of the contact and the force desired to be exertedby the staking tool.

As will be best-seen from FIGURES 4 and 5, the carrier arm 6 has leadedge 33 which has substantially the same shape as the electricalcontact. By this means the electrical contact will move in asubstantially vertical manner between the points where it is firstcontacted by the lead edge 33 as it comes from the chute 8 to theposition where it is placed in the jaws 26 of the exit guide. In thismanner, there will be no binding of the contact element in the transferchannel 35. As is seen, the chute 8 has recess therein to permit thefree movement of the ends of the electrical contact. The end of thechute 8 substantially coincides with the sides of the transfer channel 35. By means of this coincidental relationship, the carrier arm 6 mayfreely move through the entire length of the exit guide provided bychannel 35 and into the jaws 26. After the electrical contact element isfirmly positioned in the jaws :of the exit guide assembly and after thelead edge 33 of carrier arm 6 is removed, the staking tool 9 isactuated, thereby striking the electrical contact which moves downwardlyin a vertical direction through the entire length of the exit guideassembly to the aperture in the lamp. The staking tool is axiallypositioned 70 over the aperture formed by the jaws 26 of the exit guideassembly and is adapted to fit in this aperture. 1 Only a relativelysmall space is left between the end of jaws downwardly without touchingthe jig block 19. Further,

it permits easy removal of the assembled metal plate and electricalcontact. The jig 17 is designed so that the aperture of the lamp 46 isalways positioned directly be neath the staking tool 9.

In operation of this device the lamp 45 is inserted in A the jig block17. The electrical contact moves down chute 8 and into the feedingsection, where it is slidably positioned on ridge 44. The depression 45is provided in channel to permit the electrical contact to pass freelyover it. The lever arm 6 is moved, which causes the electrical contactto be transferred from the first position at the end of chute 8 to thesecond position in the jaws 26 of the exit guide which grasp fairlytightly but without sufiicient binding action to prevent the operationof the staking tool 9. After the lead edge 33 is withdrawn from the jaws26 of the exit guide, the staking tool 9 is actuated. This causes theelectrical contact to be driven into the aperture in the lamp 46, whichis then removed from the jig assembly 17 and a new lamp inserted and theoperation repeated.

The insertion of the lamp into the jig, the actuation of' the carrierarm 6, and the actuation of the staking tool 9 may be done manually orby suitable automatic device.

It is apparent that modifications in the above described system maybemade by those skilled in the art. It is my intent, however, to belimited in this invention only by the scope of the appended claims. 1

As our invention we claim: 1. Apparatus for inserting electrical contactelements into an aperture in a solid plate, said apparatus comprise ing:means for retaining a batch source of electrical contact elementsdisposed at the upper end of a sloping chute, said sloping chute beingadapted to receive electrical contact elements from said batch sourceand deliver them to a feeding channel disposed at the lower end thereof;a pair of opposed, vertically elongated, spaced apart jaws afiixed to anend of said feeding channel, said jaws adapted to grasp and temporarilyretain an electrical contact element. transferred from said chute alongsaid channel; a carrier arm slidably supported within said feedingchannel, said carrier arm adapted to effectuate said transfer from said.chute to said jaws and simultaneously retain additional electricalcontact elements within said chute; a vertically elongated staking toolsupported above the space formed by said jaws, said staking tool adaptedto strike said electrical contact element temporarily retained thereinand drive said element into said aperture; means to actuate said stakingtool to strike said retained electrical contact element and therebydrive said element into said aperture;

cans for supporting all of the mechanisms aforesaid in a cooperativerelationship. p

2. The apparatus according to claim 1 further corn-' prising a means toretain said solid plate having an aper ture therein, said means beingdisposed beneath an exit guide means formed by said spaced-apart jaws,said exit guide means vertically extending to immediately above saidmeans to retain said solid plate whereby said plate may be freelyinserted and removed therefrom.

References Cited in the file of this patent UNITED STATES PATENTSHeidergott Mar. 24, 1959

1. APPARATUS FOR INSERTING ELECTRICAL CONTACT ELEMENTS INTO AN APERTUREIN A SOLID PLATE, SAID APPARATUS COMPRISING: MEANS FOR RETAINING A BATCHSOURCE OF ELECTRICAL CONTACT ELEMENTS DISPOSED AT THE UPPER END OF ASLOPING CHUTE, SAID SLOPING CHUTE BEING ADAPTED TO RECEIVE ELECTRICALCONTACT ELEMENTS FROM SAID BATCH SOURCE AND DELIVER THEM TO A FEEDINGCHANNEL DISPOSED AT THE LOWER END THEREOF; A PAIR OF OPPOSED, VERTICALLYELONGATED, SPACED APART JAWS AFFIXED TO AN END OF SAID FEEDING CHANNEL,SAID JAWS ADAPTED TO GRASP AND TEMPORARILY RETAIN AN ELECTRICAL CONTACTELEMENT TRANSFERRED FROM SAID CHUTE ALONG SAID CHANNEL; A CARRIER ARMSLIDABLY SUPPORTED WITHIN SAID FEEDING CHANNEL, SAID